Komatsu Hydraulic Mining Shovel PC7000-6 Operation & Maintenance Manual – PDF DOWNLOAD

Komatsu Hydraulic Mining Shovel PC7000-6 Operation & Maintenance Manual – PDF DOWNLOAD

DESCRIPTION:

Komatsu Hydraulic Mining Shovel PC7000-6 Operation & Maintenance Manual – PDF DOWNLOAD

SERIAL NUMBER 35005

1.1BEFORE READING THIS MANUAL
This manual gives details of the operation and methods of inspection and maintenance for this machine that must be obeyed in order to use the machine safely. Most accidents are caused by the failure to follow fundamental safety rules for the operation and maintenance of machines.
Read, understand and follow all precautions and warnings in this manual and on the machine before performing operation and maintenance. Failure to do so may result in serious injury or death.
Komatsu cannot predict every circumstance that may involve a potential hazard when the machine is used. Therefore, the safety messages in this manual and on the machine may not include all possible safety precautions. If you carry out any operation, inspection or maintenance under conditions that are not described in this manual, understand that it is your responsibility to take the necessary precautions to ensure safety. In no event should you or others engage in prohibited uses or actions described in this manual. Improper operation and maintenance of the machine can be hazardous and could result in serious injury or death.
If you sell the machine, be sure to give this manual to the new owner together with the machine.
This manual uses the international units (SI) for units of measurement. For reference, units that have been used in the past are given in ( ).
The explanations, values, and illustrations in this manual have been prepared based on the latest information available as of the date of publication. Continuing improvements in the design of this machine may lead to additional changes that are not reflected in this manual. Consult Komatsu or your Komatsu distributor for the latest available information concerning your machine or with questions regarding information contained in this manual.
The numbers in circles in the illustrations correspond to the numbers in ( ) in the text. (For example:
Komatsu delivers machines that comply with all applicable regulations and standards of the country to which it has been shipped. If the machine has been purchased in another country, it may lack certain safety devices and specifications that are necessary for use in your country. If there is any question about whether your product complies with the applicable standards and regulations of your country, consult Komatsu or your Komatsu distributor before operating the machine.
Always keep the Operation and Maintenance Manual in the storage space provided inside the operator’s cabin (see Fig. 1-1) so that all relevant personnel can read it at any time. If this manual is lost or damaged, contact your distributor immediately to arrange for its replacement.
TABLE OF CONTENTS:

Komatsu Hydraulic Mining Shovel PC7000-6 Operation & Maintenance Manual – PDF DOWNLOAD

1 FOREWORD……………………………………………………………………………………………………………………… 9
1.1 BEFORE READING THIS MANUAL………………………………………………………………………………………………… 10
1.2 EC DECLARATION OF CONFORMITY………………………………………………………………………………………………. 11
1.3 DIRECTIONS OF THE MACHINE…………………………………………………………………………………………………. 12
1.4 SPECIFICATION AND SERIAL PLATE…………………………………………………………………………………………….. 13
1.4.1 PRODUCT IDENTIFICATION NUMBER………………………………………………………………………………………… 13
1.5 DIVISION OF THE BINDER……………………………………………………………………………………………………. 14
1.6 DESIGNATED USE OF THE SHOVEL………………………………………………………………………………………………. 15
1.7 DELIVERY OF THE SHOVEL……………………………………………………………………………………………………. 16
1.7.1 SPARE PARTS………………………………………………………………………………………………………… 16
1.7.2 SERVICE……………………………………………………………………………………………………………. 16
1.8 EXPLANATION OF ABBREVIATIONS………………………………………………………………………………………………. 17
1 SAFETY……………………………………………………………………………………………………………………….. 19
1.1 SAFETY INFORMATION……………………………………………………………………………………………………….. 20
1.2 OVERVIEW………………………………………………………………………………………………………………… 21
1.2.1 NORMAL OPERATIONS…………………………………………………………………………………………………… 21
1.2.2 REGULAR MAINTENANCE…………………………………………………………………………………………………. 21
1.2.3 TROUBLESHOOTING, ADJUSTMENTS AND REPAIR……………………………………………………………………………….. 21
1.2.4 ADDITIONAL SAFETY PRECAUTIONS………………………………………………………………………………………… 21
1.3 SOUND PRESSURE AND VIBRATION LEVELs IN THE OPERATOR’S CAB…………………………………………………………………….. 22
1.3.1 SOUND……………………………………………………………………………………………………………… 22
1.3.2 VIBRATION………………………………………………………………………………………………………….. 22
1.4 GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR……………………………………………………………………… 23
1.4.1 UNDERSTANDING THE MACHINE……………………………………………………………………………………………. 23
1.4.2 PRECAUTIONS BEFORE STARTING OPERATION ON THE EXCAVATOR………………………………………………………………….. 23
1.4.2.1 ENSURING SAFE OPERATION………………………………………………………………………………………… 23
1.4.3 PREPARATIONS FOR SAFE OPERATION………………………………………………………………………………………. 23
1.4.3.1 PRECAUTIONS REGARDING SAFETY RELATED EQUIPMENT……………………………………………………………………. 23
1.4.3.2 INSPECTING THE MACHINE…………………………………………………………………………………………. 23
1.4.3.3 WEAR WELL FITTING CLOTHES AND PROTECTIVE EQUIPMENT………………………………………………………………… 24
1.4.3.4 KEEP MACHINE CLEAN…………………………………………………………………………………………….. 24
1.4.3.5 PRECAUTIONS INSIDE OPERATOR’S COMPARTMENT………………………………………………………………………… 24
1.4.3.6 PROVIDE FIRE EXTINGUISHER AND FIRST AID KIT………………………………………………………………………. 25
1.4.3.7 IF A PROBLEM IS FOUND………………………………………………………………………………………….. 25
1.4.4 FIRE PREVENTION…………………………………………………………………………………………………….. 25
1.4.4.1 PRECAUTIONS TO PREVENT FIRE…………………………………………………………………………………….. 25
1.4.4.2 ACTION IF FIRE OCCURS………………………………………………………………………………………….. 27
1.4.4.3 EMERGENCY EXIT FROM OPERATOR’S CAB………………………………………………………………………………. 27
1.4.5 PRECAUTIONS WHEN GETTING ON OR OFF THE MACHINE…………………………………………………………………………. 28
1.4.5.1 USE HANDRAILS AND STEPS WHEN GETTING ON OR OFF THE MACHINE…………………………………………………………. 28
1.4.5.2 NO JUMPING ON OR OFF THE MACHINE………………………………………………………………………………… 28
1.4.5.3 NO PEOPLE ON THE ATTACHMENT…………………………………………………………………………………….. 28
1.4.5.4 WORKING IN HIGH PLACES…………………………………………………………………………………………. 28
1.4.5.5 LEAVING OPERATOR’S SEAT WITH LOCK……………………………………………………………………………….. 29
1.4.5.6 LEAVING THE MACHINE……………………………………………………………………………………………. 29
1.4.6 BURN PREVENTION…………………………………………………………………………………………………….. 29
1.4.6.1 Hot coolant…………………………………………………………………………………………………… 29
1.4.6.2 Hot oil………………………………………………………………………………………………………. 30
1.4.7 PRECAUTIONS WHEN CLEANING CAB GLASS…………………………………………………………………………………… 30
1.4.8 PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES…………………………………………………………………………… 30
1.4.8.1 UNAUTHORIZED MODIFICATION………………………………………………………………………………………. 31
1.4.8.2 PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS……………………………………………………………………. 31
1.4.9 ELECTROMAGNETIC COMPATIBILITY (EMC)…………………………………………………………………………………… 31
1.4.10 PRECAUTIONS AT JOBSITE……………………………………………………………………………………………… 32
1.4.10.1 VISIBILITY FROM OPERATOR’S SEAT………………………………………………………………………………… 33
1.4.10.2 CAMERA SYSTEM WITH MONITORS……………………………………………………………………………………. 33
1.4.10.3 ENSURE GOOD VISIBILITY………………………………………………………………………………………… 33
1.4.10.4 CHECKING SIGNS AND SIGNALMAN’S SIGNALS………………………………………………………………………….. 33
1.4.10.5 INVESTIGATE AND CONFIRM JOBSITE CONDITIONS………………………………………………………………………. 34
1.4.10.6 DO NOT GO CLOSE TO HIGH VOLTAGE CABLES………………………………………………………………………….. 34
1.4.10.7 WORKING ON LOOSE GROUND……………………………………………………………………………………….. 35
1.4.10.8 GAS, DUST, STEAM AND SMOKE…………………………………………………………………………………….. 35
1.4.10.9 VENTILATION OF ENCLOSED AREAS………………………………………………………………………………….. 36
1.4.11 STARTING motor…………………………………………………………………………………………………….. 37
1.4.11.1 WARNING TAG………………………………………………………………………………………………….. 37
1.4.11.2 CHECKS BEFORE STARTING motor…………………………………………………………………………………… 37
1.4.11.3 PRECAUTION WHEN STARTING motor…………………………………………………………………………………. 37
1.4.11.4 PRECAUTION IN COLD AREAS………………………………………………………………………………………. 38
1.4.12 OPERATION…………………………………………………………………………………………………………. 38
1.4.12.1 CHECKS BEFORE OPERATION……………………………………………………………………………………….. 38
1.4.12.2 PRECAUTIONS WHEN TRAVELLING IN FORWARD OR REVERSE………………………………………………………………… 39
1.4.12.3 PRECAUTIONS WHEN travelling……………………………………………………………………………………. 40
1.4.12.4 TRAVELLING ON SLOPES………………………………………………………………………………………….. 41
1.4.12.5 OPERATIONS ON SLOPES………………………………………………………………………………………….. 42
1.4.12.6 PROHIBITED OPERATIONS…………………………………………………………………………………………. 42
1.4.12.7 TRAVELLING ON FROZEN OR SNOW COVERED SURFACES……………………………………………………………………. 43
1.4.12.8 PARKING THE MACHINE…………………………………………………………………………………………… 43
1.4.12.9 TRANSPORTATION……………………………………………………………………………………………….. 43
1.5 PRECAUTION FOR MAINTENANCE………………………………………………………………………………………………… 44
1.5.1 GENERAL PRECAUTIONS…………………………………………………………………………………………………. 44
1.5.1.1 SELECTION AND QUALIFICATION OF PERSONNEL – BASIC RESPONSIBILITIES…………………………………………………… 45
1.5.1.2 STOP motor FOR MAINTENANCE……………………………………………………………………………………… 46
1.5.1.3 WARNING TAG…………………………………………………………………………………………………… 47
1.5.1.4 KEEP WORKPLACE CLEAN AND TIDY…………………………………………………………………………………… 48
1.5.1.5 APPOINT LEADER WHEN WORKING WITH OTHERS………………………………………………………………………….. 48
1.5.1.6 TWO WORKERS FOR MAINTENANCE WHEN THE MACHINE IS RUNNING……………………………………………………………. 49
1.5.1.7 INSTALLING, REMOVING OR STORING ATTACHMENTS………………………………………………………………………. 49
1.5.1.8 PRECAUTIONS WHEN WORKING UNDER THE MACHINE OR EQUIPMENT……………………………………………………………. 50
1.5.1.9 NOISE………………………………………………………………………………………………………… 50
1.5.1.10 WHEN USING A HAMMER…………………………………………………………………………………………… 50
1.5.1.11 PROPER TOOLS…………………………………………………………………………………………………. 51
1.5.1.12 ACCUMULATOR………………………………………………………………………………………………….. 51
1.5.1.13 PERSONNEL……………………………………………………………………………………………………. 51
1.5.2 PRECAUTIONS FOR INSPECTION AND MAINTENANCE…………………………………………………………………………….. 52
1.5.2.1 PRECAUTION WHEN WELDING………………………………………………………………………………………… 52
1.5.2.2 BATTERY HANDLING………………………………………………………………………………………………. 52
1.5.3 PRECAUTIONS WITH HIGH PRESSURE FLUID………………………………………………………………………………….. 53
1.5.3.1 PRECAUTIONS WITH HIGH FUEL PRESSURE……………………………………………………………………………… 53
1.5.3.2 HANDLING HIGH PRESSURES HOSES OR PIPES…………………………………………………………………………… 54
1.5.3.3 REPLACEMENT OF HOSE LINES………………………………………………………………………………………. 54
1.5.3.4 INSPECTION OF HOSE LINES……………………………………………………………………………………….. 54
1.5.3.5 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…………………………………………………………………….. 55
1.5.3.6 PRECAUTIONS FOR HIGH VOLTAGE……………………………………………………………………………………. 55
1.5.3.7 AIR CONDITIONING MAINTENANCE……………………………………………………………………………………. 55
1.5.3.8 COMPRESSED AIR………………………………………………………………………………………………… 56
1.5.3.9 WASTE MATERIALS……………………………………………………………………………………………….. 56
1.6 ADDITIONAL SAFETY INFORMATION FOR TROUBLESHOOTING AND ADJUSTMENTS……………………………………………………………… 57
1.6.1 INSPECTION OF THE HYDRAULIC SYSTEM……………………………………………………………………………………. 57
1.6.2 TWO WORKERS ONLY WHEN THE MACHINE IS RUNNING DURING ADJUSTMENTS………………………………………………………….. 57
1.6.3 AREAS OF POTENTIAL DANGER AROUND THE EXCAVATOR…………………………………………………………………………. 57
1.7 SPECIAL SAFETY EQUIPMENT………………………………………………………………………………………………….. 58
1.7.1 FRONT GUARD PROTECTIVE STRUCTUR ’FOPS’ FOR OPERATOR’S CAB……………………………………………………………….. 59
1.7.2 OBJECT HANDLING…………………………………………………………………………………………………….. 59
1.7.3 LIGHTING…………………………………………………………………………………………………………… 59
1.7.4 WARNING BEACON……………………………………………………………………………………………………… 59
1.7.5 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD)…………………………………………………………….. 59
1.7.5.1 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD)……………………………………………………….. 59
1.7.5.2 INSTRUCTIONS FOR USE…………………………………………………………………………………………… 61
1.7.5.3 PRIOR TO USING THE HARNESS (1), THE WEARER SHALL………………………………………………………………….. 63
1.7.5.4 RECOMMENDATIONS FOR USE OF THE HOLDING HOOKS AND HOLD- BACK HOOKS OF THE SAFETY HARNESS……………………………….. 63
1.7.5.5 INSTRUCTIONS FOR USE…………………………………………………………………………………………… 65
2.8 SAFETY WARNING SIGNS……………………………………………………………………………………………………… 67
2.8.1 LOCATION AND DESCRIPTION OF THE SIGNS…………………………………………………………………………………. 68
3 OPERATION…………………………………………………………………………………………………………………….. 85
3.1 FOREWORD………………………………………………………………………………………………………………… 86
3.2 CONSTRUCTION OF THE SHOVEL………………………………………………………………………………………………… 87
3.2.1 OVERALL VIEW……………………………………………………………………………………………………….. 87
3.2.2 UNDERCARRIAGE AND SUPERSTRUCTURE……………………………………………………………………………………… 88
3.2.2.1 SUPERSTRUCTURE………………………………………………………………………………………………… 90
3.2.2.2 MACHINERY HOUSE……………………………………………………………………………………………….. 92
3.2.3 HYDRAULICALLY OPERATED ACCESS LADDER………………………………………………………………………………….. 94
3.2.3.1 Lowering the ladder in emergency situations………………………………………………………………………. 97
3.2.4 EMERGENCY ESCAPE LADDERS…………………………………………………………………………………………….. 98
3.2.4.1 Emergency escape from the operator’s cabin……………………………………………………………………….. 99
3.2.4.2 Emergency escape from the Machinery house…………………………………………………………………………101
3.2.4.3 Emergency escape from the machinery house roof…………………………………………………………………….103
3.2.4.4 ESCAPE LADDER WINCH ASSEMBLY…………………………………………………………………………………….105
3.2.5 BOOM ACCESS LADDER AND WALKWAY………………………………………………………………………………………..106
3.2.6 ENGINE SHUTDOWN FROM GROUND MAN OR OPERATOR WARNING SYSTEM……………………………………………………………….108
3.2.6.1 Engine Shutdown System actuated from Ground Man (Special Equipment)………………………………………………….109
3.2.6.2 Operator Warning System (Special Equipment)……………………………………………………………………….109
3.2.7 OPERATOR’S CAB WITH INTEGRATED FALLING OBJECT PROTECTIVE STRUCTURE (FOPS)………………………………………………….110
3.2.7.1 Operator’s Cab – Emergency Escape Hammer and Storage Box for Operation Manual…………………………………………115
3.2.7.2 Operator’s Seat Adjustment………………………………………………………………………………………117
3.2.7.3 Co-driver’s Seat and Refrigerator Box…………………………………………………………………………….118
3.2.7.4 INSTRUCTIONS TO using and looking after THE SEAT BELTS……………………………………………………………..119
3.2.8 ENGINE OIL MANAGEMENT SYSTEM………………………………………………………………………………………….120
3.2.8.1 Oil Burning System “Centinel” combined with Oil Supply System “Reserve”………………………………………………123
3.2.8.2 Eliminator Engine Oil Filtration System…………………………………………………………………………..124
3.3 OPERATOR’S CAB – CONTROLS………………………………………………………………………………………………….126
3.3.1 CONTROLS WITH BACKHOE ATTACHMENT………………………………………………………………………………………126
3.3.1.1 Hydraulic Control System………………………………………………………………………………………..127
3.3.1.2 Safety Circuit for Controls……………………………………………………………………………………..127
3.3.1.3 Control Pattern………………………………………………………………………………………………..129
3.3.2 CONTROLS WITH BOTTOM DUMP BUCKET ATTACHMENT…………………………………………………………………………….130
3.3.2.1 Hydraulic Control System………………………………………………………………………………………..131
3.3.2.2 Safety Circuit for Controls……………………………………………………………………………………..131
3.3.2.3 Control Pattern………………………………………………………………………………………………..133
3.3.2.4 Automatic Float Position for Boom and Stick……………………………………………………………………….133
3.3.3 OPERATOR’S CONSOLE…………………………………………………………………………………………………..135
3.3.3.1 Control Panel………………………………………………………………………………………………….137
3.3.3.2 Switch Board…………………………………………………………………………………………………..139
3.3.4 INTERFACE PANEL FOR DIAGNOSTICS……………………………………………………………………………………….141
3.4 VEHICLE HEALTH MONITORING SYSTEM (Komtrax Plus)– HEALTH MONITOR………………………………………………………………..142
3.4.1 SEQUENCE OF DISPLAYS…………………………………………………………………………………………………143
3.4.2 OPENING SCREEN………………………………………………………………………………………………………143
3.4.3 MAIN GAUGE SCREENS 1 TO 4…………………………………………………………………………………………….144
3.4.3.1 Main Gauge Screen 1…………………………………………………………………………………………….145
3.4.3.2 Main Gauge Screen 2…………………………………………………………………………………………….147
3.4.3.3 Main Gauge Screen 3…………………………………………………………………………………………….147
3.4.3.4 Main Gauge Screen 4…………………………………………………………………………………………….149
3.4.3.5 Color Definition……………………………………………………………………………………………….149
3.4.4 FUEL CONSUMPTION SCREEN………………………………………………………………………………………………151
3.4.5 FAILURE MESSAGE HISTORY SCREEN FOR OPERATOR…………………………………………………………………………….151
3.4.6 MAIN SCREEN – CHANGE >TIME >SMR >DATE………………………………………………………………………………….152
3.4.7 MAINTENANCE MONITOR………………………………………………………………………………………………….152
3.4.7.1 Maintenance confirmation through Service Personnel…………………………………………………………………153
3.4.8 SETTINGS FOR OPERATOR………………………………………………………………………………………………..153
3.4.9 AUTOMATIC MESSAGES…………………………………………………………………………………………………..158
3.4.9.1 Automatic Messages……………………………………………………………………………………………..158
3.4.9.2 Automatic Messages……………………………………………………………………………………………..160
Automatic Engine Messages………………………………………………………………………………………………161
3.5 OPERATING THE HEATER, VENTILATION AND AIR CONDITIONING………………………………………………………………………..162
3.5.1 Digital Display……………………………………………………………………………………………………..162
3.5.2 Luminous Indication………………………………………………………………………………………………….164
3.6 CAMERA SYSTEM WITH MONITORS………………………………………………………………………………………………..166
3.6.1 LOCATION OF MONITORS AND CONTROL UNITS…………………………………………………………………………………167
3.6.1.1 Operating the Monitors………………………………………………………………………………………….169
3.6.1.2 Ajustments of the Monitor……………………………………………………………………………………….169
3.6.1.3 Arrangement of the Cameras………………………………………………………………………………………173
3.7 MACHINERY HOUSE…………………………………………………………………………………………………………..174
3.7.1 EMERGENCY ENGINE SHUTDOWN SWITCHES…………………………………………………………………………………….175
3.7.2 SAFETY SWITCH FOR MAINTENANCE…………………………………………………………………………………………177
3.7.3 CONTROL AND FILTER PANEL OF REAR- AND FRONT POWER UNIT…………………………………………………………………..179
3.8 ELECTRICAL EQUIPMENT IN CAB BASE……………………………………………………………………………………………180
3.8.1 COMPONENTS IN CAB BASE……………………………………………………………………………………………….181
3.8.2 MASTER TURBO CONTROLLER MTC – LED INDICATIONS…………………………………………………………………………..183
3.8.3 BINARY FAULT CODE LIST……………………………………………………………………………………………….190
Combination Message 308 Trouble Can-Bus or Can Hardware……………………………………………………………………192
3.8.4 TABLE OF LOCATION NUMBERS FOR ELECTRICAL COMPONENTS……………………………………………………………………..192
3.9 CHECKS BEFORE STARTING THE ENGINES………………………………………………………………………………………….194
3.9.1 Coolant Level……………………………………………………………………………………………………….197
3.9.1.1 HYDRAULIC SYSTEM – CHECK OIL LEVEL……………………………………………………………………………….199
3.9.1.2 Machinery House Doors…………………………………………………………………………………………..199
3.9.1.3 OPERATOR’S SEAT ADJUSTMENT………………………………………………………………………………………199
3.10 STARTING THE ENGINES……………………………………………………………………………………………………..200
3.10.1 STARTING PROCEDURE………………………………………………………………………………………………….203
3.10.1.1 Cold Weather Starting at ambient Temperatures below –25°C and to –40°C………………………………………………205
3.10.2 ENGINE WARM-UP……………………………………………………………………………………………………..211
3.10.3 HYDRAULIC OIL WARM-UP……………………………………………………………………………………………….211
3.11 MOVING THE SHOVEL………………………………………………………………………………………………………..213
3.11.1 TRAVEL CONTROL WITH FOOT PEDALS………………………………………………………………………………………213
3.11.1.1 TRAVEL ALARM / BACK-UP ALARM……………………………………………………………………………………215
3.11.2 TRAVELLING INSTRUCTIONS……………………………………………………………………………………………..215
3.11.2.1 TRAVELLING LONG DISTANCES………………………………………………………………………………………217
3.12 SLEWING AND BRAKING THE SUPERSTRUCTURE……………………………………………………………………………………..218
3.12.1 SLEWING THE SUPERSTRUCTURE…………………………………………………………………………………………..218
3.12.1.1 MACHINES WITH “EURO” CONTROL……………………………………………………………………………………218
3.12.1.2 MACHINES WITH “” CONTROL……………………………………………………………………………………….219
3.12.1.3 BRAKING THE SUPERSTRUCTURE……………………………………………………………………………………..219
3.12.1.4 Hydraulic slew brake actuated by hydraulic access Ladder and Service Arm of Central Refilling System……………………220
3.12.1.5 Important Instructions for Slewing the Superstructure……………………………………………………………..220
3.13 WORKING WITH THE ATTACHMENT……………………………………………………………………………………………….221
3.13.0.1 FACE SHOVEL BUCKET………………………………………………………………………………………………..222
3.13.1 COMBINED OPERATION CYCLES……………………………………………………………………………………………223
3.14 WORKING INSTRUCTIONS……………………………………………………………………………………………………..225
3.14.1 STABILITY OF THE SHOVEL……………………………………………………………………………………………..225
3.14.2 FURTHER OPERATING PRACTICES………………………………………………………………………………………….227
3.14.3 Loading Trucks……………………………………………………………………………………………………..231
3.15 PARKING THE SHOVEL……………………………………………………………………………………………………….232
3.15.0.1 CLEANING THE TRACK GROUPS………………………………………………………………………………………….232
3.16 STOPPING THE ENGINES……………………………………………………………………………………………………..233
3.16.1 RELIEVE PRESSURE IN THE HYDRAULIC SYSTEM………………………………………………………………………………236
3.17 OPERATION OF THE LUBRICATION SYSTEM………………………………………………………………………………………..237
3.17.1 CENTRAL LUBRICATION SYSTEM ”CLS”……………………………………………………………………………………..237
3.17.1.1 Manual actuation of the central lubrication system………………………………………………………………..237
3.17.1.2 ADJUSTMENTS OF THE CENTRAL LUBRICATION SYSTEM…………………………………………………………………….238
3.17.2 SWING CIRCLE PINION LUBRICATION SYSTEM ”SLS”…………………………………………………………………………..238
3.17.2.1 Manual actuation of the swing circle lubrication system……………………………………………………………239
3.17.2.2 SWING CIRCLE LUBRICATION SYSTEM ”SLS”……………………………………………………………………………240
3.17.2.3 ADJUSTMENTS OF THE SWING CIRCLE LUBRICATION SYSTEM………………………………………………………………..240
3.17.2.4 Defining the Lubrication System Greasing Areas……………………………………………………………………240
3.18 TRANSFER PUMP FOR HYDRAULIC OIL……………………………………………………………………………………………241
3.18.1 OPERATING THE TRANSFER PUMP………………………………………………………………………………………….242
3.18.2 TRANSFUSION PROCEDURE……………………………………………………………………………………………….244
3.19 CENTRAL REFILLING SYSTEM………………………………………………………………………………………………….247
3.19.1 SYSTEMS CONNECTED TO THE REFILLING SYSTEM……………………………………………………………………………..248
3.19.2 OPERATING THE HYDRAULIC SERVICE ARM…………………………………………………………………………………..250
3.19.3 RECEIVER PANEL WITH MONITOR BOX………………………………………………………………………………………252
3.19.3.1 Refilling Procedure:…………………………………………………………………………………………..256
3.19.4 REFILLABLE GREASE CONTAINERS OF THE AUTOMATIC LUBRICATION SYSTEMS………………………………………………………..258
3.20 WORK ON THE LOADER ATTACHMENT……………………………………………………………………………………………..259
3.20.0.1 OBSERVE THE FOLLOWING INSTRUCTIONS………………………………………………………………………………….259
3.21 TRANSPORTATION AND LIFTING OF THE SHOVEL……………………………………………………………………………………260
3.21.1 DISASSEMBLING OF THE SHOVEL………………………………………………………………………………………….260
3.21.2 TRANSPORTATION AND LIFTING…………………………………………………………………………………………..260
3.22 RETRIEVAL PROCEDURE………………………………………………………………………………………………………261
3.22.1 GENERAL……………………………………………………………………………………………………………261
3.23 SHOVEL STORAGE…………………………………………………………………………………………………………..262
3.23.1 GENERAL……………………………………………………………………………………………………………262
3.23.2 PREPARING FOR STORAGE……………………………………………………………………………………………….262
3.23.3 ONE MONTH REPETITIVE SERVICE PERIOD…………………………………………………………………………………..262
3.23.4 SIX MONTH REPETITIVE SERVICE PERIOD…………………………………………………………………………………..262
3.23.5 PREPARING FOR OPERATION……………………………………………………………………………………………..263
3.24 TROUBLE SHOOTING…………………………………………………………………………………………………………264
3.24.1 GENERAL……………………………………………………………………………………………………………264
3.24.2 ENGINE…………………………………………………………………………………………………………….264
3.24.3 HYDRAULIC SYSTEM……………………………………………………………………………………………………265
3.24.4 FINAL DRIVES AND SWING GEAR………………………………………………………………………………………….266
3.24.5 CRAWLER TRACKS……………………………………………………………………………………………………..266
4 MAINTENANCE……………………………………………………………………………………………………………………267
4.1 FOREWORD…………………………………………………………………………………………………………………268
4.1.1 DEFINITIONS…………………………………………………………………………………………………………268
4.1.2 GENERAL RECOMMENDATIONS………………………………………………………………………………………………268
4.2 PRECAUTIONS FOR MAINTENANCE………………………………………………………………………………………………..269
4.3 FLUIDS AND LUBRICANTS……………………………………………………………………………………………………..270
4.3.1 LUBRICANTS FOR OPERATION IN COLD AND ARCTIC CLIMATES…………………………………………………………………….270
4.3.2 FLUIDS AND LUBRICANTS FOR MODERATE AND HOT CLIMATES……………………………………………………………………..271
4.3.2.1 Recommended Hydraulic Oils………………………………………………………………………………………272
4.3.2.2 General Information to selecting hydraulic oils……………………………………………………………………273
4.4 FILLING CAPACITIES………………………………………………………………………………………………………..275
4.5 STANDARD TORQUE LIST………………………………………………………………………………………………………276
4.5.1 Torque for Flange Joints……………………………………………………………………………………………..277
4.5.2 TORQUES FOR SPECIAL COMPONENTS………………………………………………………………………………………..278
4.6 LUBRICATION AND MAINTENANCE SCHEDULE………………………………………………………………………………………..280
4.6.1 INITIAL AND FIRST SERVICING…………………………………………………………………………………………..280
4.6.1.1 INITIAL RUNNING-IN……………………………………………………………………………………………..280
4.6.1.2 AFTER THE FIRST 250 OPERATING HOURS………………………………………………………………………………280
4.6.1.3 AFTER THE FIRST 1000 OPERATING HOURS OR AFTER COMPONENT REPLACEMENT………………………………………………….280
4.6.2 SERVICING THE CRITICAL BOLT CONNECTIONS………………………………………………………………………………..281
4.6.3 PERIODIC SERVICING INTERVALS………………………………………………………………………………………….281
4.6.3.1 WHEN NECESSARY…………………………………………………………………………………………………282
4.6.3.2 EVERY 10 OPERATING HOURS OR DAILY………………………………………………………………………………..282
4.6.3.3 EVERY 50 OPERATING HOURS OR WEEKLY……………………………………………………………………………….282
4.6.3.4 EVERY 250 OPERATING HOURS OR MONTHLY……………………………………………………………………………..283
4.6.3.5 EVERY 500 OPERATING HOURS OR QUATERLY…………………………………………………………………………….283
4.6.3.6 EVERY 1000 OPERATING HOURS OR 6 MONTHLY…………………………………………………………………………..284
4.6.3.7 EVERY 2000 OPERATING HOURS OR YEARLY……………………………………………………………………………..284
4.6.3.8 EVERY 3000 OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR…………………………………………………………….285
4.6.3.9 EVERY 6000 OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR…………………………………………………………….285
4.6.4 MAINTENANCE SCHEDULES OF FILTER ELEMENTS AND OTHER COMPONENTS…………………………………………………………….286
4.7 SAFETY CRITICAL PARTS……………………………………………………………………………………………………..287
4.7.1 REPLACEMENT OF HYDRAULIC HOSE LINES AND FUEL HOSE LINES………………………………………………………………….287
4.7.2 INSPECTION OF HOSE LINES……………………………………………………………………………………………..288
4.7.3 PERIODIC REPLACEMENT OF FURTHER SAFETY CRITICAL PARTS……………………………………………………………………288
4.8 EXTENDED SERVICE INTERVALS FOR ENGINES WITH ENGINE OIL MANAGEMENT SYSTEM………………………………………………………..291
4.8.0.1 Servicing Intervals………………………………………………………………………………………………..291
4.8.0.2 Extended Service Intervals for Engines with Engine Oil Management System…………………………………………………295
4.8.1 MAINTENANCE OF THE ENGINES……………………………………………………………………………………………295
4.8.2 ENGINE FUEL FILTER LOCATIONS………………………………………………………………………………………….297
4.8.2.1 Cleaning Practices Before Working on the Fuel System……………………………………………………………….299
4.8.3 VENTING THE AIR FROM THE FUEL FILTERS………………………………………………………………………………….301
4.9 FIRST SERVICING…………………………………………………………………………………………………………..302
4.9.1 WORKING ATTACHMENT – INITIAL CHECKS FOR PROPER LUBRICATION……………………………………………………………….302
4.9.2 ATTACHMENT – CHECK GREASE INJECTORS AND GREASE CONNECTIONS……………………………………………………………….303
4.9.3 CAR BODY AND RACEWAY OF SLEW RING – CHECK GREASE INJECTORS AND GREASE CONNECTIONS…………………………………………..304
4.9.4 SWING CIRCLE Pinion – CHECK GREASE INJECTORS AND GREASE CONNECTIONS……………………………………………………….305
4.9.5 Swing circle – Check Torque OF BOLT CONNECTIONS…………………………………………………………………………306
4.9.6 Retightening procedure of the crawler carrier mounting bolts……………………………………………………………..307
4.9.6.1 Procedure for ENSURING Proper Tightening OF the crawler carrier mounting bolts………………………………………..308
4.9.6.2 Special hydraulic torque wrench………………………………………………………………………………….309
4.10 WHEN NECESSARY…………………………………………………………………………………………………………..310
4.10.1 ENGINE AIR CLEANER MAINTENANCE……………………………………………………………………………………….311
4.10.1.1 Check the Dust Cup…………………………………………………………………………………………….311
4.10.1.2 Servicing the filter elements…………………………………………………………………………………..313
4.10.1.3 Replacing the safety filter element (4) if necessary:……………………………………………………………..313
4.10.1.4 General Service Tips…………………………………………………………………………………………..313
4.10.2 CYLINDER ROD PROTECTION (IF EQUIPPED), CHANGE SLIDING BLOCKS…………………………………………………………….315
4.10.3 SWING CIRCLE TOOTHING LUBRICATION…………………………………………………………………………………….317
4.10.4 AUTOMATIC LUBRICATION SYSTEMS FILL GREASE CONTAINERS……………………………………………………………………319
4.10.4.1 Service the Grease Filters for Refillable Grease Containers………………………………………………………..321
4.10.5 GUIDE WHEELS – REPLACE FLOATING SEALS…………………………………………………………………………………321
4.11 EVERY 10 OPERATING HOURS OR DAILY………………………………………………………………………………………….322
4.11.1 WALK – AROUND INSPECTION…………………………………………………………………………………………….323
4.11.2 CYLINDER ROD PROTECTION (IF EQUIPPED), VISUAL Check…………………………………………………………………….327
4.11.3 RADIATORS – CHECK COOLANT LEVEL………………………………………………………………………………………329
4.11.4 TRACK GROUPS – CLEAN………………………………………………………………………………………………..329
4.11.4.1 BOOM – CHECK LADDER AND WALKWAY…………………………………………………………………………………331
4.11.5 CAMERA SYSTEM………………………………………………………………………………………………………333
4.11.6 EMERGENCY ESCAPE ROUTE FROM OPERATOR’S CAB…………………………………………………………………………….335
4.12 EVERY 50 OPERATING HOURS OR WEEKLY…………………………………………………………………………………………336
4.12.0.1 Swing gears………………………………………………………………………………………………………337
4.12.1 TRAVEL GEARS, MOTOR ADAPTER HOUSINGS AND FINAL DRIVES CHECK OIL LEVELS……………………………………………………339
4.12.1.1 TRAVEL GEAR BOX – CHECK OIL LEVEL……………………………………………………………………………….341
4.12.1.2 MOTOR ADAPTER HOUSINGS – CHECK OIL LEVEL…………………………………………………………………………341
4.12.1.3 FINAL DRIVE HOUSING – CHECK OIL LEVEL……………………………………………………………………………341
4.12.1.4 TRAVEL GEARS, MOTOR ADAPTER HOUSINGS AND FINAL DRIVES – CHECK BREATHER FILTERS……………………………………….343
4.12.2 PTOs (PUMP DISTRIBUTOR GEARS) – CHECK OIL LEVEL………………………………………………………………………..345
4.12.2.1 PTOs (PUMP DISTRIBUTOR GEARS), CHECK OIL LEVEL:…………………………………………………………………..345
4.12.2.2 Main Hydraulic Pumps – Check Oil Level in Drive Shaft Housings……………………………………………………..347
4.12.2.3 Auxilliary drive- Check Oil Level in Drive Shaft Housings………………………………………………………….347
4.12.3 HYDRAULIC ACCESS LADDER – CHECK SAFETY SENSOR………………………………………………………………………….349
4.12.4 HYDRAULIC OIL COOLERS – INSPECT AND CLEAN IF NECESSARY………………………………………………………………….351
4.13 EVERY 250 OPERATING HOURS OR MONTHLY……………………………………………………………………………………….352
4.13.1 AIR CONDITIONING COMPRESSOR – CHECK DRIVE BELT TENSION………………………………………………………………….353
4.13.2 SIGNAL HORN COMPRESSOR – LUBRICATE……………………………………………………………………………………355
4.13.3 HYDRAULIC OIL COOLER FAN BEARINGS – CHECK FOR LEAKAGE AND CLEAN BREATHER FILTER……………………………………………355
4.13.4 RADIATOR FAN BEARINGS – CHECK FOR LEAKAGE AND CLEAN BREATHER FILTER………………………………………………………355
4.13.5 AUTOMATIC LUBRICATION SYSTEM – CLEAN BREATHER FILTER ON PUMP STATION……………………………………………………..357
4.13.6 CABIN AIR CLEANER – INSPECT………………………………………………………………………………………….359
4.13.7 AIR CONDITIONING FOR OPERATOR’S CAB – CHECK REFRIGERANT LEVEL……………………………………………………………361
4.13.8 WINDSHIELD WASHER SYSTEM – CHECK FLUID LEVEL…………………………………………………………………………..363
4.13.9 CABIN HEATER FILTER – INSPECT………………………………………………………………………………………..365
4.14 EVERY 500 OPERATING HOURS OR QUARTERLY……………………………………………………………………………………..366
4.14.1 BATTERIES – CHECK FLUID LEVEL………………………………………………………………………………………..367
4.14.1.1 GREASE INJECTORS – CHECK INDICATOR STEMS…………………………………………………………………………368
4.14.1.2 CORRECTIVE ACTIONS…………………………………………………………………………………………….368
4.14.2 CYLINDER ROD PROTECTION (IF EQUIPPED), Inspect…………………………………………………………………………371
4.14.3 FUEL TANK………………………………………………………………………………………………………….373
4.14.3.1 Drain Water and Sediments from Fuel Tank…………………………………………………………………………373
4.14.3.2 Servicing the Fuel System………………………………………………………………………………………373
4.14.4 CRAWLER TRACK – INSPECTION…………………………………………………………………………………………..375
4.14.4.1 CHECK ADJUSTING RANGE OF GUIDE WHEELS……………………………………………………………………………375
4.14.4.2 CHECK ADJUSTING RANGE FOR GUIDE WHEELS…………………………………………………………………………..377
4.14.4.3 CHECK ADJUSTING RANGE FOR GUIDE WHEELS…………………………………………………………………………..379
4.14.4.4 Bleeding the System……………………………………………………………………………………………379
4.14.5 GROUND CABLES OF ENGINE AND ALTERNATOR – CHECK FOR CORRECT CONNECTION…………………………………………………….381
4.14.6 GROUND CABLE OF OPERATOR’S CAB – CHECK FOR CORRECT CONNECTION……………………………………………………………383
4.14.7 EMERGENCY ESCAPE LADDERS…………………………………………………………………………………………….385
4.14.7.1 TEST FUNCTIONALITY…………………………………………………………………………………………….385
4.14.7.2 Lubricating…………………………………………………………………………………………………..385
4.14.8 EMERGENCY LOWERING OF ACCESS LADDER – TEST FUNCTIONALITY………………………………………………………………..387
4.15 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH…………………………………………………………………………………388
4.15.1 Critical Bolt Connections……………………………………………………………………………………………389
4.15.1.1 Check mounting of Operator’s cab………………………………………………………………………………..389
4.15.1.2 Check tightening torque of the counterweight mounting bolts,……………………………………………………….391
4.15.1.3 Check condition and fastening of both swing gears (01) and swing motors (02)…………………………………………393
4.15.2 EMERGENCY ENGINE SHUTDOWN SWITCHES – TEST FUNCTIONALITY…………………………………………………………………395
4.15.2.1 TEST MAINTENANCE SAFETY SWITCH (11)……………………………………………………………………………..397
4.15.3 ENGINE SHUTDOWN PULL CHAINS (SPECIAL EQUIPMENT) – TEST FUNCTIONALITY……………………………………………………..397
4.15.4 ELECTRICAL EQUIPMENT – MAINTENANCE……………………………………………………………………………………399
4.15.5 CABIN AIR CLEANER – REPLACE PRIMARY FILTER…………………………………………………………………………….401
4.15.6 HYDRAULIC SYSTEM – FILTER SERVICE…………………………………………………………………………………….403
4.15.6.1 FILTER SERVICE………………………………………………………………………………………………..405
4.15.7 BLEEDING AIR FROM THE RETURN OIL CHAMBERS……………………………………………………………………………..407
4.15.8 PTO’S (PUMP DISTRIBUTOR GEARS), SWING GEARS AND TRAVEL GEARS – OIL SAMPLE ANALYSIS…………………………………………419
4.15.8.1 Oil drain plugs……………………………………………………………………………………………….419
4.15.9 SIGNAL HORN COMPRESSOR – CLEAN AND LUBRICATE…………………………………………………………………………..421
4.15.10 HYDRAULIC TRACK TENSIONING SYSTEM – CHECK PRESSURE ACCUMULATORS…………………………………………………………423
4.15.11 HYDRAULIC OIL COOLER – INSPECT AND LUBRICATE DOOR HINGES……………………………………………………………….425
4.15.12 MACHINERY HOUSE DOORS – INSPECT AND LUBRICATE DOOR HINGES………………………………………………………………427
4.16 EVERY 2000 OPERATING HOURS OR YEARLY……………………………………………………………………………………….428
4.16.1 HYDRAULIC SYSTEM – CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER……………………………………………..429
4.16.1.1 HYDRAULIC SYSTEM – CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER………………………………………..431
4.16.1.2 HYDRAULIC SYSTEM – CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER………………………………………..433
4.16.1.3 Replace Suction Strainers of Main Pumps………………………………………………………………………….437
4.16.2 FILLING THE HYDRAULIC SYSTEM…………………………………………………………………………………………439
4.16.3 BLEEDING THE HYDRAULIC SYSTEM………………………………………………………………………………………..441
4.16.4 EMERGENCY ESCAPE LADDERS – INSPECTION…………………………………………………………………………………445
4.16.5 PREVENTATIVE MAINTENANCE (PM) CLINIC – PERFORM TEST…………………………………………………………………….447
4.16.6 EMERGENCY ESCAPE ROUTE FROM OPERATOR’S CAB…………………………………………………………………………….449
4.16.6.1 Functionality…………………………………………………………………………………………………449
4.17 EVERY 3000 OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR………………………………………………………………………450
4.17.0.1 SWING GEAR……………………………………………………………………………………………………….451
4.17.1 TRAVEL GEARS, MOTOR ADAPTER HOUSINGS AND FINAL DRIVES CHANGE OIL…………………………………………………………455
4.17.2 PTO (PUMP DISTRIBUTOR GEAR) – CHANGE OIL………………………………………………………………………………459
4.17.3 FLEXIBLE COUPLING – VISUAL CHECK……………………………………………………………………………………..461
4.18 CRITICAL BOLT CONNECTIONS – EVERY 3000 OPERATING HOURS……………………………………………………………………….462
4.18.1 Critical BOLT CONNECTIONS – CHECK TORQUE LOAD………………………………………………………………………….463
4.18.1.1 Hydraulic Access Ladder………………………………………………………………………………………..465
4.18.1.2 Check fastening and condition of railings (A, B, C, D and E)……………………………………………………….467
4.18.1.3 Check fastening and condition of cab base………………………………………………………………………..469
4.18.1.4 Check fastening and condition of fuel tank……………………………………………………………………….471
4.18.1.5 Check fastening and condition of hydraulic oil cooler……………………………………………………………..473
4.18.1.6 Check fastening and condition of hydraulic oil tank……………………………………………………………….475
4.18.1.7 Check fastening of power house frame (01) to superstructure main frame………………………………………………477
4.18.1.8 Check fastening and condition of the eight power house posts……………………………………………………….479
4.18.1.9 Power House Louvers……………………………………………………………………………………………481
4.18.1.10 Power house Roof……………………………………………………………………………………………..483
4.18.1.11 Check mounting and security of Diesel engines and pump distributor gears……………………………………………485
4.18.1.12 Check mounting and security of each Diesel engine and pump distributor gear…………………………………………487
4.18.1.13 Main Hydraulic pumps………………………………………………………………………………………….489
4.18.1.14 Check fastening and condition of control valve carrier, main control valves (I, II and III) and swing control valve (5)….491
4.18.1.15 Check condition and fastening of swivel joint (A)………………………………………………………………..493
4.18.1.16 Crawler Carrier………………………………………………………………………………………………495
4.18.1.17 Check condition and fastening of railings (01/02) and of steps (03, 04, 05 and 23)…………………………………..499
4.18.1.18 Roof-mounted crane for grease barrel replacement (special equipment) Check condition and fastening of the crane…………501
4.19 EVERY 6000 HOURS HOWEVER AT LEAST ONCE A YEAR……………………………………………………………………………….502
4.19.1 AUTOMATIC LUBRICATION SYSTEMS – replace pump outlet GREASE FILTERS……………………………………………………….503
4.19.2 HYDRAULIC Oil TANK – CHECK LEAKAGE OIL SCREEN FILTER……………………………………………………………………505
4.19.3 CHANGING THE HIGH PRESSURE FILTERS……………………………………………………………………………………507
4.20 FIRE PREVENTION………………………………………………………………………………………………………….508
4.20.1 PRECAUTIONS………………………………………………………………………………………………………..509
4.21 WELD REPAIRS…………………………………………………………………………………………………………….510
4.21.1 GENERAL INFORMATION…………………………………………………………………………………………………510
4.21.1.1 GENERAL PROTECTIVE MEASURES…………………………………………………………………………………….511
4.21.2 WELD REPAIRS ON MAJOR COMPONENTS OF THE EXCAVATOR………………………………………………………………………511
4.21.2.1 COUNTERWEIGHT…………………………………………………………………………………………………511
4.21.3 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE UNDERCARRIAGE…………………………………………………….513
4.21.4 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE LOADER ATTACHMENT…………………………………………………515
4.21.5 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE SUPERSTRUCTURE……………………………………………………517
4.21.5.1 Electrical Units in Cab Base,…………………………………………………………………………………..519
4.21.5.2 Engine Electronics…………………………………………………………………………………………….519
4.21.6 AFTER FINISHING THE WELD REPAIRS ON THE SUPERSTRUCTURE………………………………………………………………….519

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